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 Hits: 698 Size: 57.71 KB Posted: 10/6/11 This is the axle donor. Apparently, everything after '97 is coil-sprung/IRS. |  Hits: 547 Size: 51.55 KB Posted: 10/6/11 This one had the same axle, but others of the same year range have a smaller lug pattern, so pay clo... |  Hits: 668 Size: 85.74 KB Posted: 10/6/11 I chose this donor because the brackets are designed to mount to a nearly-flat surface. Only the re... |  Hits: 737 Size: 94.08 KB Posted: 10/6/11 This cost less than $100, which is less than a cheap trailer axle alone. This one includes brakes, ... |  Hits: 541 Size: 84.32 KB Posted: 10/6/11 Just measurements taken during the planning stage. |
 Hits: 575 Size: 77.66 KB Posted: 10/6/11 Just measurements taken during the planning stage. |  Hits: 502 Size: 96.44 KB Posted: 10/6/11 I chose this axle for its deep drop. The lack of ground clearance doesn't matter since the cross tu... |  Hits: 634 Size: 73.65 KB Posted: 10/6/11 The shocks hang slightly lower than the drums, which is perfect - they're expendable, so they'll pro... |  Hits: 527 Size: 85.75 KB Posted: 10/6/11 This axle has the common 5-on-4.5" lug circle, but the larger 2.8" hub stickout, so rims s... |  Hits: 527 Size: 82.7 KB Posted: 10/6/11 Just measurements taken during the planning stage. |
 Hits: 607 Size: 88.73 KB Posted: 10/6/11 Just measurements taken during the planning stage. |  Hits: 1538 Size: 135.64 KB Posted: 10/6/11 While checking the fit without the brackets, I found the front bolts seized in their bushings. This... |  Hits: 1237 Size: 118.2 KB Posted: 10/6/11 While checking the fit without the brackets, I found the front bolts seized in the bushings. This b... |  Hits: 1121 Size: 101.62 KB Posted: 10/6/11 Small wonder they were seized - I doubt any amount of hammering would have removed them. Certainly ... |  Hits: 646 Size: 87.97 KB Posted: 10/6/11 Just checking - nothing is drilled or bolted yet. |
 Hits: 599 Size: 71.64 KB Posted: 10/6/11 Just checking - nothing is drilled or bolted yet. |  Hits: 612 Size: 82.28 KB Posted: 10/6/11 Just checking - nothing is drilled or bolted yet. |  Hits: 618 Size: 77.16 KB Posted: 10/6/11 Just checking - nothing is drilled or bolted yet. |  Hits: 587 Size: 65.38 KB Posted: 10/6/11 Just checking - nothing is drilled or bolted yet. |  Hits: 591 Size: 99.94 KB Posted: 10/6/11 Eventually, I settled on this orientation: the front brackets bolted to the web of the I-beam, and t... |
 Hits: 587 Size: 97.12 KB Posted: 10/6/11 I'll probably reinforce the holes thru the flanges, but this is good enough to get it rolling. |  Hits: 572 Size: 71.85 KB Posted: 10/6/11 The gap is almost exactly 3/4", so I'll use plywood for the deck. |  Hits: 638 Size: 100.1 KB Posted: 10/6/11 To prep it for welding, the frame is strapped together. |  Hits: 557 Size: 93.33 KB Posted: 10/6/11 A carbide-tipped rip blade works surprisingly well on Aluminum. Even thick stuff. |  Hits: 615 Size: 110.32 KB Posted: 10/6/11 The floor joists are a snug fit. |
 Hits: 603 Size: 97.43 KB Posted: 10/12/11 I've tacked the tongue together, and it's pinned to the leaf spring brackets so the deck can tilt. |  Hits: 585 Size: 95.58 KB Posted: 10/12/11 The tongue is long enough that the frame clears a fullsize truck bumper, and the jack is back enough... |  Hits: 578 Size: 95.12 KB Posted: 10/13/11 The single L e-brake cable has been swapped for a 2-piece R so they match. I'll cut the tubular guid... |  Hits: 556 Size: 100.71 KB Posted: 10/13/11 27.5" should be just enough room between the front 2 floor joists for a hidden spare tire. |  Hits: 542 Size: 100.2 KB Posted: 10/25/11 I borrowed a Lincoln wire-feed and burned the tongue together. It's certainly not professional-qual... |
 Hits: 500 Size: 82.35 KB Posted: 10/26/11 I finally came up with an idea for the the e-brake cable brackets that eliminates one set of tubes, ... |  Hits: 522 Size: 89.48 KB Posted: 10/26/11 The cable easily clears the tire, and will have even more room after I add the 2" wheel spacers. |  Hits: 546 Size: 83.78 KB Posted: 10/26/11 There's a tab behind the spring backet that prevents it from rotating on the single bolt. |  Hits: 520 Size: 99.62 KB Posted: 10/26/11 The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t... |  Hits: 523 Size: 99.36 KB Posted: 10/26/11 The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t... |
 Hits: 520 Size: 95.16 KB Posted: 10/26/11 The tongue tilts on the front spring brackets. The center of the deck is very slightly forward of t... |  Hits: 595 Size: 63.47 KB Posted: 10/31/11 This is the first time I've actually fitted everything at once. The shock mounts will have to move ... |  Hits: 526 Size: 70.69 KB Posted: 10/31/11 The slot on the other side was too high - the bolt hit the frame. So I swapped the tubes & cut the ... |  Hits: 512 Size: 94.9 KB Posted: 10/31/11 The ammo can will hold straps, spare lug nuts, tire chocks (etc.), and the lug wrench stows neatly b... |  Hits: 531 Size: 102.85 KB Posted: 11/3/11 2-inch spacers are just what it needed to clear the frame. |
 Hits: 535 Size: 98.39 KB Posted: 11/3/11 These spacers came from eBay. They're not listed for a '97 Caravan because the lug threads are diff... |  Hits: 506 Size: 110.84 KB Posted: 11/11/12 I finally found some junkyard lift struts that would fit & work to hold the deck tilted, and install... |  Hits: 508 Size: 112.02 KB Posted: 11/11/12 I finally found some junkyard lift struts that would fit & work, and installed them. To keep them fr... |  Hits: 469 Size: 106.07 KB Posted: 11/11/12 I finally found some junkyard lift struts that would fit & work to hold the deck tilted, and install... |  Hits: 408 Size: 78.34 KB Posted: 6/15/13 To keep the pin from ever going missing, I cabled it to the trailer. |
 Hits: 424 Size: 92.69 KB Posted: 6/15/13 Cables on the front of the spare tray will keep it from sagging, or the spare from sliding too far f... |  Hits: 445 Size: 87.58 KB Posted: 6/15/13 These little covers should be enough to keep me legal, and they're just strong enough for me to sit ... |  Hits: 477 Size: 95 KB Posted: 6/15/13 These little wheel covers should be enough to keep me legal, and they're just strong enough for me t... |  Hits: 578 Size: 108.44 KB Posted: 8/1/13 The stake pockets are spaced the same, so these rails fit in any position.
The fiberglass reflectiv... | |